Ingrain carpet fabric



2 Sheets-Sheet 1.

(Specimens.)

S .J.A(JHESON., INGRAIN CARPET FABRIC.

Patented May 16,1893.

W4. MM w A UNITED STATES PATENT OFFICE.

SAMUEL J. ACl-IESON, OF PLAINFIELD, NEW JERSEY.

INGRAIN CARPET FABRIC.

SPECIFICATION forming part of Letters Patent No. 497,294, dated May 16,1893.

. Application filed November 14, 4892. Serial No. 5 ,343- ($peoimens.)

To all whom it may concern:

Be it known that I, SAMUEL J. Aonnson, a citizen of the United States,residing at Plainfield, in the county of Union and State of New Jersey,have invented certain new and useful Improvements in Ingrain CarpetFabrics, of which the following is a specification.

In weaving ordinary two ply ingrain or Scotch carpets four warps andfour wefts are employed in each set or weave. Two of these wefts andtheir corresponding warps are interwoven to form one ply or cloth andthe other two wefts and warps are interwoven to form another ply orcloth. These cloths are usually of different shades and are boundtoget-her to form the pattern by being reversed, so that one ply orcloth is at the face at one point in the carpet and the other ply is atthe face at other parts thereof. In such a carpet four wefts areemployed in each set so that only four colors are possible. In order toincrease the number of colors in the fabric the use of five instead offour wefts has been suggested and hitherto this fifth or extra weft hasbeen inserted in the set and located in the back ply. In some cases twoof the regular warps of the set have been caused to perform extra dutyin binding in the additional weft; such a fabric possessed obviousdisadvantages, for example, the two regular warps that served to tie inthe fifth or extra weft were necessarily passed very frequently from theface to the back of the fabric, and consequently a greater length ofthem was required than of the other two regular warps, so that thesetwowarps by reason of their extra duty were subjected to considerablestrain and were required to stretch to accommodate themselves to theexcessive looping to which they were subjected. Moreover, in bindingfive wefts with four warps, it is nec essary that two wefts shouldoccupy the same shed at various points in the fabric and that theadjacent or contiguous face wefts of two succeeding sets should be tiedby warps that pass between them and around underlying back wefts,whereby the face wefts are drawn apart and thus exposing the underlyingwefts. These disadvantageous features resulted in an impaired qualityand affected the usefulness of the finished fabric, because the drawingapart of certain of the contiguous face weft threads exposed theunderlying wefts to view, thus giving a fabric of motley appearance andof a character commonly designated as having grinning eifects, and theunequal use of two of the warps, that is, those doing extra duty in thebinding of the additional or fifth weft, required that such should be ofelastic and strong yarn or thread, which is very expensive. In thisconnection it may be remarked that even when such yarn was employed itbecame necessary frequently to re verse the plies in order to equalizeall the warps utilized and this frequent reversal of the plies limitsand greatly restricts the choice of pattern, because only small figuresof frequent occurrence can be employed, in order to permit of theaccomplishment of these frequent reversals. In other cases the extra orfifth weft has been inserted into the same shed with one of the fourregular wefts at the back of the fabric and only three warps wereemployed for binding in the fifth weft. In such cases the warps wereused unequally and conscquently were subjected to unequal strain and hadto be of good quality, but were expensive. The insertion of the twowefts in one shed on the back of the fabric and beneath one weft on theface thereof causes the back wefts to be visible from the face and thusgives rise to grinning which produces a motley effect. Moreovenin thisfabric the pattern must be frequently changed, otherwise the excessivelyunequal use of certain of the warps causes the fabric to be drawn andpuckered. In both of these five weft fabrics an attempt is I frequentlymade to obviate grinning by utilizing an extra number of wefts to theinch on the face and driving or beating up the wefts very hard. Thisexcessive beating up in a measure corrects the grinning, but it alsoresults in the production of a comparatively short length of carpet incomparison with the excessive quantity of both warp and weft employed.Moreover, the employment of an extra number of wefts to the inch on theface, results in the production of a heavy and expensive fabric.

The principal objects of my invention are first, to obviate the abovementioned defects and disadvantages and to provide a durable andcomparatively inexpensive carpet fabric having five wefts in each setand having an increased length in proportion to its weight; second, toimprove the capacity of such a fabric for effective and perfectcoloring; and third, to weave the carpet in such manner that it may bemade of a heavy or light weight as required and with a smooth unmottledface free from grinning effects.

My invention consists of the improved carpet fabric hereinafterdescribed and claimed.

The nature, characteristic features and scope of my invention will bemore fully understood from the following description taken in connectionwith the accompanying drawings forming part hereof; and in which- Figure1, is a diagrammatic view drawn in two parts of which the one at thebottom is a continuation of the right hand end of the one at the top andshowing a section taken in the direction of the warps, t'. 2., a sectionthrough the wefts, illustrating various ar rangeinents of threads in acarpet fabric embodying features of my invention and illustrating eachweft knit or bound in a separate shed and also illustrating three setsof warps that interchangeably bind certain wefts at the back andface ofthe fabric; and Fig. 2, is a diagrammatic view illustrating the tieup ofa loom and the cards for producing the first two sets of the fabricembodying my invention and illustrated in Fig. 1.

In my improved fabric the warp is divided into five divisions, of whichfour, 1, 2, 3, 4, may be regarded as the usual four warps of an ordinaryingrain carpet, that is, the black, olive, red and white warps. Thefifth division may be of any color, for example, drab, and is employedinterchangeably with two of said four warps, for example, with the whitewarp 4 and olive warp 2, for tying in certain of the wefts on the back.Ordinarily a thread appertaining to each set passes through each dent orsplit in the reed and consequently only five warps are shown in Fig. 1,but any other preferred arrangement of the warps in respect to the dentsor splits of the reed may be employed, provided it permits of theoperation of the warps in the manner hereinafter described.

Although my invention relates particularly to the manipulation anddisposition of the fifth and two of the regular four warps, in thepresent instance the white warp 4, olive warp 2, and drab warp 5, stillfor the sake of a further description, it will be assumed that certainwefts are introduced into the fabric in accordance with a requiredpattern, yet nevertheless it must be distinctly understood that myinvention is not limited to the employment of any particular colororwefts. Assuming therefore that the pattern illustrated in Fig. 1, isemployed and referring to said figures, b is a black weft, w is a whiteweft, r, is a red weft, 0, is an olive weft, and d, is a fifth or extraweft that may be of any color and is in the present instance assumed tobe of a drab color. These wefts are assumed to be thrown or shot intothe fabric in the order named. In Fig. 1, nine sets, numbered from 1 to9 inclusive, are shown as separated by dotted lines, and each setcomprises five warps and five wefts, whereof two are in the face ply orweft plane and three are in the back ply or weft plane. In the face plyor weft plane, the red warp 3 always ties in a red weft r, and theolive, white and drab warps 2, 4 and 5 interchangeably tie in the weftsw, 0 and d, so that the warps 2, 4 and 5, share the work of tying in theextra weft. This is important, because it enables equal lengths of saidwarps 2, 4 and 5 to be employed. In the back ply or weft plane the redwarp 8, ties in the black weft b, the black warp 1, ties in the red weftr, and the warps 2, 4 and 5 are employed for interchangeably tying inthe wefts w, oand (Z, whereby equal lengths of all the warps areemployed in the production of the fabric.

From the foregoing description it appears that the drab or extra warp 5,affords means interchangeable with two of the warps 1, 2, 3 and 4, inthe present instance the warps 2 and 4, for binding in three of thewefts, in the present instance, the wefts d, 0 and to, so that each ofthe five wefts is tied or bound in a shed by itself and so that thequantity of the warps employed is equalized, because the extra or drabwarp 5, is passed around certain of the wefts instead of the warps 2 and4, whereby the latter are relieved of this duty. This substitution ofthe warp 5, for one of the warps 2 and 4, also prevents the drawing ofthe face wefts apart and the consequent grinning that occurs in a fabrichaving five wefts and four warps in a set and hereinabove referred to,because it obviates the necessity for passing two warps around two backwefts and between two face wefts. Inasmuch as each weft is tied in aseparate shed and all the warps are used equally or substantially so, itfollows that an extra number of wefts to theinch need not be employed onthe face and that the wefts of the fabric need not be beaten up hard inorder to prevent grinning, so that a comparatively great length of goodfabric is obtained from a given weight of yarn, and so that light orheavy weight fabrics having perfectly smooth faces free from grinning,may be produced to meet the different demands of trade. Assuming thatthe extra warp 5, is employed in connection with the regular warps 4 and2, as has been hereinabove explained and for the sake of a furtherdescription of the interchangeable use of the warps 4, 2 and 5, forbinding in the wefts w, 0 and (1, reference may be had to Fig. 1. Insaid figure the white weft w, is tied on the face at set 1, by the whitewarp 4, at set 3, by the olive warp 2, and at set 6, by the drab warp 5.The olive weft 0, is tied on the face at sets 1 and 7 by the olive warp2, at set 8, by the white warp 4, and at set 9, by the drab warp 5. Thedrab weft cl, is tied on the face at set4 by the drab warp 5, at set 5by the white warp 4, and at set 6 by the olive warp 2. From theforegoing description it is apparent that the warps 2, 4 and 5interchangeably bind in one of the three wefts w, 0 and d on the face.In the present instance each of the wefts w, 0 and d, is tied in on theface at different sets by each of the warps 2, 4 and 5. On the back atset 2, the weftso and (Z, are both tied in by the drab warp 5 and theweft 0, is also tiedin by the white warp 4. At set 3 on the back thewefts 0 and d, are both tied in by the white warp 4, and the weft d, isalso tiedin by the drab warp 5. On the back at set 7, the wefts w and d,are tied in by the olive warp 2 and drab Warp 5, at set 8, by the whitewarp 4 and olive warp 2, and at set 9, by the drab warp 5 and white warp4, so that the warps 2, 4and 5, interchangeably tie in two of the weftsw, 0 and d, on the back.

The hereinabove described carpet fabric may be produced in the followingmanner, reference being had more especially to Fig. 2, of the drawings.

In weaving myimproved fabric use may be made of a loom provided with asingle lifter board a, having the tails 0.,of one half of the slots (tturned in one direction and the tails 0. of the other half of the slotsa turned in the other direction, and with a five sided card cylinder 1).On one side of this card cylinder is a right hand set of cards 0, whichmake the figure, and on the other side of this cylinder is a left handset of cards e, which make the ground. Two sets of small cards areemployed, because they are more convenient than one set of large cards.The jacquard has eight rows of needles for each card, 2'. a, eight rowsof needleson each side. On the right hand side the needles appertainingto the rows 2, 4, 6 and 8 are connected respectively with a single tailattached to a single black warp 1, and the needles appertaining to thefour rows 1, 3,5 and 7, are provided respectively with a single tailconnected with a single red warp 3. On the left hand side four rows ofneedles 2, 4, 6 and 8 each control a single olive warp 2, and the otherfour do double duty and control two tails. The rows 1 and 5, appertainrespectively to two White warps 2, and the rows 3 and 7, appertainrespectively to two extra or drab warps 5. The five sets of tailsappertaining to the five sets of warps are disposed inacumber board f,equal to five journals at rest, in such manner that the tails of theblack warp 1, are at the back, olive 2 next, red 3 next, white 4 next,and drab or extra 5, at the front. It being understood that there is onelift of the board a, and a new pair of cards for each shot of weft andthat the warps are operated solely by the Jacquard machine and cards.

In order that the manipulation of the drab warp 5, and of twoof thewarps 1, 2, 3 and 4, in the present instance the olive warp 2 and whitewarp 4, whereby they are used interchangeably, may be fully understood,a description will now be given of the way in which the cards are cut.

The black weft b: The first card right side, the rows 2, 4, 6 and 8appertaining to the black warp 1, are cut; this causes the black warpthreads to be lifted when the board rises and constitutes the equivalentof the back journal lift. First card left side, where black weft is togo to the back or wrong side of the fabric, as at sets 1, 5, 6, 7,Fig. 1. This card is blank so that warps 2, 4 and 5 are lifted, andwhere the black weft b, is to go to the face or right side of thefabric, as at sets 2, 3 and 4 Fig. 1. This card is cut so that warps 2,4and 5 are at rest.

The white weft w, the second card left side: On this card the first andfifth rows are left blank, the other rows cut. This causes the whitewarp to be lifted when the board rises and gives the equivalent of awhite journal lift as at sets 1, 3 and 6, Fig. 1, in which the whiteweft goes to the face. However, the rows 3 and 7, of this card, may beleft blank and all the other rows cut, in order to lift the extra ordrab warp 5, as at set 7, or the rows 2, 4, 6 and 8, may be left blankand the other rows cut, in order to lift the olive warp 2, or the rows 1and 5 may be cut in order to lift the extra or drab warp 5 and whitewarp 4, as at set 2, in which the white weft is at the back, so that thewarps 3,4and 5, may be used interchangeably for bindingin the whiteweft. Second card, right side: All that part of this card where theWhite weft is to go to the face is blank and all that part where thewhite weft is to go to the back is cut.

Red Weft, third card, right side: The rows 1, 3, 5 and 7 are cut to liftthe red warp in an equivalent manner to a journal lift. Third card, leftside: This card is out where the red weft is to go to the face and isblank where the red weft is to go to the back.

Olive weft, fourth card, left side: The rows 1, 3, 5 and 7, are cut andthe other rows are blank to lift the olive warp 2, in substantially themanner thata journal lift would do. All the rest of this card is blankso that the white and extra warps 4 and 5 are down. Fourth card, righthand side: This card is uncut where the olive weft is to go to the faceand is out where the olive weft is to go to the back.

Drab weft,fifth card,left side: In this card the four rows 2, 4, 6 and 8are left blank, in order to lift the olive warp over the weft (l, andthis card is instrumental in efiecting the peculiar arrangement of thewarp threads that embody my invention, because the weft d, on the backis covered by the regular white warp 4, of the set. It being understoodthat in this instance the rows 1 and 5 are cut and the rows 3 and 7 areblank. Fifth card, right side, wherethe drab weft d, is to go to theface: This card is blank, so that the olive warp is up, and where thedrab weft is to go to the back this card is cut, so that all the warpsexcept the'white are up.

Black weft: The sixth pair of cards are similar to the first.

White weft, seventh card, left side: On this card the rows 3 and 7 areblank to lift the extra warp 5 over the white weft, as shown at sets 2and 7, in Fig. 1, so that the latter on the face as in the seventh setof Fig. 1, may be tied in by a different set of warps than was used forthis purpose in the first five white wefts of Fig. 1, and in thisinstance the rows 1, 2, 4, 5, 6 and 8 are out. It may be remarked thatto let the olive warps 2 bind the white weft at the back, as in set 2,of Fig. 1, the rows 2, 4, 6 and 8 must be cut. Seventh card, right side:When the white weft is to go to the face the card is blank and when itis to go to the back, the card is cut.

Red Weft: The eighth pair of cards is out like the third pair of cards.

Olive weft: The ninth pair of cards is out like the fourth pair ofcards.

Drab weft, left side, tenth card: In this card a difierent set of warpsare employed to bind on the back from those used in the fifth white weftof Fig. 1, by leaving the rows 1, 2, 4, 5, 6 and 8 blank and cutting therows 3 and 7. This leaves the extra warps at rest and the other rows arecut or left blank according as the olive and the white warps are to belifted, but in the present instance they are left blank. Tenth card,right side: This card is the same as the fifth card of the set.

From the foregoing description it appears that before the white weft w,olive weft 0, and drab weft d, are shot or picked, a left hand cardcomes into action, and inasmuch as certain needles appertaining to thiscard control the white warps 4, certain other needles the olive warps 2,and certain other needles the drab warps 5, it follows that any one ofthese warps may be employed in each set for passing over any one of thethree wefts or binding them in on the face by leaving blanks on thecards corresponding to the needles appertaining to the selected warpsand perforating the card for the other needles. In the present instancethis selection is assumed to have been made at sets 1 and 3 withrelation to the white weft w, at sets 7, 8 and 9 with relation to theolive weft 0, and at sets 4, 5 and (5 with relation to the drab weft d,for example, in Fig. 1: 1 the olive weft 0, is tied at set 7, by thewarp 2, at set 8 by the warp 4, and at set 9, by the .warp 5; theselection being made in the cutting of the cards as has already beenexplained. Since in each set one of the warps 2, 4 and 5 is selected topass over one of the three wefts w, 0 and d, on the face, it followsthat the warp so selected cannot also pass under such weft in the sameset, so that the warps 2, 4 and 5, may be interchangeably passed underonly the two remaining wefts. In the case of sets 7, 8 and 9, under thewefts w and d, or in other words interchangeably used to bind in the tworemaining of the three wefts on the back. The choice or selection of thethree warps is made in respect to the two wefts at the back in suchmanner that no two wefts occupy the shed and in such manner thatsubstantially equal lengths of warps are employed throughout the fabric.For example in Fig. l at set 1, the warp 4, is selected to pass over thewhite weft w, and either of the warps 2, 4 and 5 might have beenselected in the preparation of the corresponding left hand cards to passunder the two remaining wefts 0 and d. However, in this instance thewarp 5, passes under the weft 0, and the warp 4, under the weft d.

Having thus described the nature and objects of my invention, what Iclaim as new, and desire to secure by Letters Patent, is

The herein described homogeneous two weft plane carpet fabric having ineach set or weave five weft threads with five warp threads tying saidwefts in separate sheds and three of said warps interchangeably bindingin one of three of said wefts on the face and two of said three wefts onthe back so that substantially equal lengths of warp threads aremaintained throughout the fabric, substantially as and for the purposesset forth.

In witness whereof I have hereunto set my signature in the presence oftwo subscribing witnesses.

SAMUEL J. AOHESON.

Witnesses:

WM. ALLAN, JOHN NEAGLE.

